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<p>This study utilized novel tungsten alloy micro-particles fabricated via the cost-effective Blasting Erosion Arc Machining (BEAM) technology to perform micro-shot peening on flexspline steel specimens. A systematic comparison was conducted with traditional atomized cast steel and ceramic micro-particles, evaluating key performance indicators such as surface topography, roughness, micro-hardness distribution, residual stress fields, X-ray diffraction phase analysis, electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM) micro-structural characterization. The influence of peening intensity on surface strengthening was also investigated. The results indicate that tungsten alloy micro-shot peening achieves a surface roughness of <i>Ra</i> 1.216 μm, a maximum residual compressive stress of  −733 MPa and a compressive stress depth of 110 μm. It also yields a superior surface hardness of 471.2 HV and a hardened layer depth of 135 μm, while maintaining excellent surface integrity. Microstructural analysis reveals refined subsurface grains with an average size of 0.4 μm, a high dislocation density of 3.756×10<sup>15</sup> m<sup>−2</sup>, and a kernel average misorientation (KAM) of 0.73°, significantly exceeding the results obtained with both comparative media. TEM observations further confirm the formation of nanograins in the top surface layer. Gradient experiments on peening intensity demonstrate a systematic enhanement in strengthening effects across both mechanical properties and micro-structural characteristics with increasing intensity, offering practical insights for optimizing process parameters. These findings collectively underscore the superiority of tungsten alloy micro-particles over cast steel and ceramic micro-particles in enhancing surface mechanical properties and micro-structural refinement. Consequently, BEAM-fabricated tungsten-alloy micro-particles combine economical production with high performance, demonstrating significant promise for industrial surface enhancement applications.</p> Graphical Abstract <p></p>

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Micro-shot Peening Performance of Flexspline Steel Specimens Using Novel Tungsten Alloy Micro-particles: Comparative Analysis with Traditional Media

  • 期刊论文

  • 发表日期：

    2026年5月19日

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  • Jiansheng Liu,
  • Kunlun Ni,
  • Feifei Zhang,
  • Kai He,
  • Hui Xu

摘要

This study utilized novel tungsten alloy micro-particles fabricated via the cost-effective Blasting Erosion Arc Machining (BEAM) technology to perform micro-shot peening on flexspline steel specimens. A systematic comparison was conducted with traditional atomized cast steel and ceramic micro-particles, evaluating key performance indicators such as surface topography, roughness, micro-hardness distribution, residual stress fields, X-ray diffraction phase analysis, electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM) micro-structural characterization. The influence of peening intensity on surface strengthening was also investigated. The results indicate that tungsten alloy micro-shot peening achieves a surface roughness of Ra 1.216 μm, a maximum residual compressive stress of  −733 MPa and a compressive stress depth of 110 μm. It also yields a superior surface hardness of 471.2 HV and a hardened layer depth of 135 μm, while maintaining excellent surface integrity. Microstructural analysis reveals refined subsurface grains with an average size of 0.4 μm, a high dislocation density of 3.756×1015 m−2, and a kernel average misorientation (KAM) of 0.73°, significantly exceeding the results obtained with both comparative media. TEM observations further confirm the formation of nanograins in the top surface layer. Gradient experiments on peening intensity demonstrate a systematic enhanement in strengthening effects across both mechanical properties and micro-structural characteristics with increasing intensity, offering practical insights for optimizing process parameters. These findings collectively underscore the superiority of tungsten alloy micro-particles over cast steel and ceramic micro-particles in enhancing surface mechanical properties and micro-structural refinement. Consequently, BEAM-fabricated tungsten-alloy micro-particles combine economical production with high performance, demonstrating significant promise for industrial surface enhancement applications.

Graphical Abstract